Knotted tuft fabric and method of weaving same



Dec. 8, 1936.

w. A. RICE ET AL 2,063,853 KNOTTED TUFT FABRIC AND METHOD OF WEAVING SAME Filed Jan. 28, 1955 5 Sheets-Shejc 1 INVENTORS Waller A. Rice, and FranK G. 6115. mm.

Dec. 8, w A RICE ET AL KNOTTED TUFT FABRIC AND METHOD OF WEAVING SAME Filed Jan. 28, 1935 5 Sheets-Sheet 2 INVENTOR UZxl'Tev A awe, and. I

Frank, 6. 6h\ BY W ORNEY 8, 1936- w. A. RICE ET AL I 2,063,853-

KNOTTED TUFT FABRIC AND METHOD OF WEAVING SAME F iled Jan. 28, 1933 5 Sheets-Sheet 4 i i 7 49 51 m 45 50 52 a a445 40 4a 50 51 |:4b 356 46 474149 42 52 14 FIG. 1 |.NVENTO.R

has ATTORNEYfi Dec. 8, 1936. w. A. RICE ET AL v 2,063,353

' KNOTTED TUFT FABRIAC AND METHOD OF WEAVING SAME Filed Jan. 28, 1933 5 Sheets-Sheet 5 INVENTORS uTqHev Phguse. BY Frank C1. fihivma- K M ORNEYS Patented Dec. 8, 1936 iii ii'iED STATEE PATENT OFFICE KNOTTED TUFT FABRHC AND METHOD OF WEAVING SAME Application January 28, 1933, Serial No. 654,046

20 Claims.

Our invention relates to an improved form of knotted tuft to be used in the production or weaving of knotted pile fabrics, such as rugs,

tapestries and plushv The principal purpose of our invention is to produce a knotted pile yarn tuft, binding together warp thread and weft thread within the same pile yarn knot.

A further purpose of our invention is to form 10. a knotted pile yarn tuft either cut or uncut which ties together in the same eye or loop of a tuft yarn knot a single warp thread or a plurality of warp threads with a single weft thread or a plurality of weft threads. We have applied this invention particularly to knotted fabrics having knots of a Selina type, that is, comprising an eye and a loop whose ends if out would form the tuft but differing from the normal Sehna knot in the inclusion of weft as well as warp thread within the eye or the loop.

A further purpose is the insertion of knotted tufts, each enclosing warp threads and weft thread in staggered alignment, thus giving the fabric a more uniform top and reducing to a large degree pile wire marks or other lines.

A further purpose is to form alternate rows of knotted tufts having all right-hand or all lefthand knots and on the same warp thread pairs with the tufts at the eye ends in successive rows spaced from each other differently than the tufts at the loop ends.

A further purpose is to form adjoining knots in line warpwise in adjoining weftwise rows, having each an eye and a loop in the same knot and located reversely in the adjoining rows, so that the terminal tufts from eye to eye are spaced a different distance lengthwise of the fabric than the distance from loop terminal to loop terminal.

A further purpose is to form a knot comprising an eye (or a loop, preferably an eye) about one or more strands of warp thread forming a warp thread and one or more strands of weft thread forming a weft thread, and a loop (or an eye, preferably a loop) about one or more strands of warp thread forming a warp thread.

A further purpose is the production of a pile fabric that can be cut to any shape or to any of various widths with a reduction of the usual amount of unravelling along the edges that takes e when cutting floor covering or fabrics due to our improved knotted tuft which is bound about both the warp threads and the weft thread or threads.

Our invention relates not only to the methods or processes involved but to the knots which are produced by them.

Further purposes will appear in the specification and in the appended claims.

We have preferred to illustrate our invention by one knot only in right and left showing and each in reverse position in successive rows, notwithstanding that we recognize that the knot may appear in other forms and settings.

Throughout the drawings the tufted pile yarn and knotted tufts are illustrated in shaded lines. The warp threads are shown in double vertical lines and the. weft threads are shown by double horizontal lines. In most of the illustrations the warp threads are illustrated the same as warp threads independently of whether they be chain warp threads or stuffer warp threads.

For the purpose of illustration and description we refer herein to the type of knot shown in Figures 1, 1a., 2, 2a, 3, '7, 13 and 17 as left-hand knots and the type shown in Figures 11), 5, 15 and 19 as right-hand knots with the thought, however, that the invention applies equally to both and that the type of knot selected is a matter largely of convenience of the designer.

Figures 1 and 1b are enlarged perspective views of left and right-hand knots respectively formed by tuft yarn about warp threads and weft threads, all separated and extended as though loosely woven.

Figure 2 is a plan view of two left-hand knotted tufts in successive rows, one in reverse formation from the other, showing the staggered effect on the face of the fabric.

Figures 1a and 2a are enlarged perspective and enlarged top plan views respectively of a plurality of adjoining tuft yarn knots in successive rows showing the pile uncut and the knots in adjoining rows as in reverse formation.

Figure 3 is a perspective View of the face of one form of our improved fabric showing lefthand knots and single placements of weft thread, such as could be inserted by a shuttle, the threads and knots being separated as though loosely I woven.

Figure 4. is a section upon line 4-4 of the structure seen in Figure 3, taken parallel with the lengths of the warp threads.

Figures 5, 7, 9, 11, 13, 15, 17 and 19 are perspective views to enlarged scale and having the threads separated as if loosely woven, showing various placings of the knots shown in Figures 1, 1b and all showing cut loops or tufts.

Figures 6, 8, 10, l2, 14, 16, 18 and 20 are sections of Figures 5, '7, 9, 11, 13, 15, 1'7 and. 19 upon lines 6-45, 8-8, lele, l2-l2, l4 l4, !6I6, 18-!8 and i i--28 respectively taken parallel with the lengths of the warp threads.

In previous hand-woven knotted pile fabric, the knots are usually of Persian or Sehna-type and are knotted about the warp threads alone, or the weft threads alone, each having its peculiar advantages. Our invention secures the advantages of both in that the knot comprises an eye and a loop, as in the Sehna knot, but either the eye or the loop, and preferably the eye, is thrown about that is, passes beneath and includes at least one warp thread with at least one weft thread. This knot is called a Schnatype knot for the reason that it is used in this different way to include within the tuft yarn of the knot both a warp thread and a weft thread, thus differing from the Sehna knot proper, which though of the same general shape includes within it either the warp or the weft, but not both.

Strictly speaking the eye of the loop surrounds and therefore passes completely about a warp thread and-if this be the part which includes the crossingalso the weft thread, whereas the loop of the knot does not completely encircle and therefore does not completely pass around either. In both cases, where the knot is inserted so that the tufts end in the upper face of the fabric, as in the illustration, the eye and the loop of the tuft yarn pass beneath the thread or threads in question. However, passing under or beneath is not sufficient for a tuft in which the yarn enters from above unless the tuft yarn comes back up to form an upper as distinguished from an under tuft end. Because there seems no proper word to apply equally to the passage of the eye completely around and the loop partly around the thread or threads, where for the purposes of breadth of claim it is desirable not to distinguish but to cover both, applicant uses the word about here to include both completely around and partly around as in the case of the eye and loop, in each case intending to mean that where the tuft appears at the top of the fabric the tuft yarn passes under or beneath the thread or threads in question.

In referring to the warp thread and to the weft thread which are included within the knot we are, of course, not intending to distinguish between warp thread comprising a single strand only and that made up of a number of strands, whether viewed as all one thread or a plurality of threads, nor to distinguish between weft thread comprising a single strand, such as could be laid by a single passage of a shuttle, and weft thread comprising several strands which could be laid by a needle or by several passages of a shuttle.

In each case there is a warp thread performing warp thread functions and a weft thread acting as such, with whatever reinforcement or subdivision may be desirable.

In the figures the weft threads have been numbered from 24 to 33, inclusive, using 24a, 25a, etc., for the additional strand where two strands appear, both treated alike. The pile yarn tufts or knots 34, 34a, etc. extend from tufts 35, 35a etc. at one terminal through eyes 36, 36a, etc., and loops 3!, 31a, etc. to tufts or terminals 38, 38a, etc., each of the eyes and each of the loops passing about one of the warp threads 4452. shown at 4043.

In Figures 1, 2, 3-10 and 15-20, it will be understood that the warp threads included within the knots, though preferably chain warp threads, need not all be chain warp threads, but can include stuffer warp threads, and that if any warp threads be not included within the knots, these additional warp threads, though preferably stuffer warp threads, can be either chain or stuffer warp threads; and that either the warp threads or the weft threads, or both, may comprise each one or more strands, the weft threads being concurrently or separately applied, as above.

We show a single Persian type, that is Sehna type knot, only in each of Figures 1 and 1b, viewing the knot of Figure l as a left-hand knot and that of Figure 1b as a right hand knot. Though both are tied upon and about and include the same two warp threads and the same weft thread, they are differently placed, the weft threads passing through the eye in one and through the loop in the other.

In both figures additional warp threads 43 and El are shown which do not pass through the knots. These may be either warp threads embraced within other knots not shown or may be free from knots and from that standpoint may be considered as idle warp threads. We prefer that the warp threads which pass through the knots shall all be chain warp threads and that any additional warp threads which do not pass through the knots, and are therefore not bound in by the knots, shall be stuffer warp threads.

For convenience of reference, merely, we have designated that side of the knot toward the observer in Figure 1 as the back of the knot and that side away from the observer in this figure as the face of the knot in order to more readily point out what, again for convenience of reference, we have called the reverse positioning or placing of the knots in Figure l as contrasted with Figure lb and in Figures 1a, 2 and 2a and 3-10. In all these latter figures knots adjoining along the lengths of the same warp threads are differently placed, two adjoining knots being back to back, for example, as in Figure 2, and each of these with its next adjoining knot being placed face to face.

Applying the above reverse placing of the knots to the four knots on any of the four pairs of warp threads in Figure 3, and counting from the upper end of the sheet downwardly, it will be seen that the first and second knots, if considered as paired are back to back. The second and third, if considered as paired are face to face. The third and fourth are again back to back.

The knots thus alternate in character along the lengths of the Warp threads throughout the fabric, adjoining knots facing reversely, that is, in different directions, so that the tuft terminals of loops 3?, 31a of the knots shown in Figure 2 are separated by a Weft thread 2'6 only, and the terminals or tufts 38 and 38a of these two loops lie quite close together; whereas the terminals 35 and 35a of the eyes 38 and 36a are spaced much more, having between them not only the weft thread 26 but the two tuft yarn thicknesses of eyes 36 and 36a and two additional weft threads 25 and 21.

As will be seen from Figures 3-10 the next knots 34b adjoining knots 34a seen in Figure 2,

Additional warp threads are will lie face to face with respect to knots 3411, the two knots 34a and 3422 will have the terminal (tufts) 35a. and 35b from their eyes close together and spaced from each other by weft threads 28, whereas the loop terminals or tufts 38 will be spaced from the loops of the knots 34a by three weft threads. The adjoining knots along the lengths of the warp threads in Figure 3, for example, are, therefore, alternately back to back and face to face. The staggering of the knots by this alternate different facing of the knots is quite desirable, whether the tufts be cut or not, in breaking up pile wire lines and other markings across the fabric and in giving a smoother appearance to the surface of the fabric formed.

Tracing out the left-hand knot of Figure 1 from the viewpoint that the yarn is woven beginning at the position of the tuft end 35, it passes downwardly between the warp thread 59 and the weft thread 25 in one quadrant formed by their crossing, diagonally across beneath the crossing point and up through the diagonally opposite quadrant formed by them to pass about the threads at the crossing and to form eye 36. The tuft yarn, now above the warp thread 50, passes across to and beneath the next warp thread 49 and upwardly beyond it forming loop 31. It thus passes about the warp thread 59 and weft thread 25 at the crossing and also about the warp thread 49.

Both the warp thread 59 and the weft thread 25 pass through the eye of the knot above, but the warp thread 49 is the only thread which passes through the loop. The eye tightly binds the warp thread and weft thread at the crossing and the loop binds the warp thread 49 to the other warp thread and to the weft thread.

In the form of Figure 1b, again tracing from the end at the tuft 35 the tuft yarn passes down and beneath warp thread 49 coming up beyond it to form an eye 36 about the warp thread 49, and then down, and diagonally beneath the crossing of the warp thread 50 and the weft thread 25 and up beyond it, terminating in the upwardly directed tuft 38.

It will be noted that the tuft yarn thus passes beneath each of the warp threads, the eye about one of these warp threads and the loop about the other; so that the warp threads are covered at these points at the back of the fabric by the tuft yarn.

In both knots in Figures 1 and 1b the closeness of the warp threads together and the fact that the weft threads and knots are beaten up into close contact step by step in the process makes the knots tremendously more effective than they would appear in the loosely separated forms of the knots illustrated.

Figures 1a and 2a are intended to illustrate the fact that the tuft yarn can be continuous and that the piles may be left uncut, forming the knot of one row reversely with respect to the knot of the other; in that with the progression of the tuft yarn from tuft 38a. in the direction of the arrows, the tuft yarn may be said to form the loop 38a of knot 34a first, followed by the eye 36a of knot 34aand by the uncut tufts 35a, 35b. Next it forms the eye 3% of knot 34b before the loop 31b, then forms tufts 38b, 38c, loop 310 and eye 36c and so on continuously, from the same tuft yarn. The structures of Figures 1a and 1b are intended to show furthermore that whether the warp threads about which the knots are formed in the other figures be chain warp threads or stuffer warp threads, knots can be formed about chain warp threads and the weft threads without in the least interfering with use of separate stuifer' warp threads 4!, 42 and 43.

The structure is well suited to a fabric which is stiffened and strengthened by stuifer warp threads and such fabric is shown in loosely woven condition so that the parts can be followed clear ly in Figures la and 2a.

Whether a stuffer warp thread be used or not, the reverse facing of the knots breaks up the tendency to a line of tuft separation across the fabric with the result that there is a tendency for lines of tuft separation to exist diagonally with respect to the fabric rather than across it.

It will be noted that each of the knots of the figures includes within the knot 34, 34a, etc., formed by the tuft yarn, a crossing 54 of warp thread with weft thread. This crossing of the threads appears within the eye of the knot in Figures 1, 1a, 2, 2a, and 3-14, whereas the crossing of the warp thread and weft thread appears within the loop in Figures 1b and 15-20. The fact that a warp thread and a weft thread both pass through the same eye or the same loop of the knot-as the case may beresults in the spacing of the tufts of an individual knot by a crossing, either by another crossing as of the same weft thread 25 with a different warp thread 49 in Figure 1 from the crossing through the eye of the loop, or by the same crossing of weft thread 25 and warp thread 59 as in Figure 1b.

Whatever the character of the knot, be it left or right, whether the knots include other warp threads than chain warp threads or not, and whether the warp and weft threads pass through the eye or through the loopof the knot, it is characteristic of our invention that warp and weft threads both pass through either the eye or the loop of the knot.

The tufts may form cut pile, as in Figures 1, 1'2) and 2-20, or may be woven as uncut pile and left so, as in Figures 1a and 2a. This is a matter of preference, though the tufts will ordinarily be cut.

Whether the tufts of the pile yarn be cut or uncut, the tufts will be staggered if the knots be placed alternately face to face and back to back, the result being a more uniform appearance of the fabric and minimal appearance of pile wire lines if the knots be made by a wire loom, or of other marks or lines.

In Figures 1a and 2a the tuft yarn forms successive knots warpwise upon the same warp threads in each row, but upon different weft threads-every other weft threadprogressively. For example, taking up the knots formed with eyes about warp thread 50 and starting with the loop tuft 38a of knot 34a, the eye 36a of this knot is formed about the warp thread at its juncture with weft thread 21.

The tuft 35a from the eye of this knot is continuous with the tuft 35b of knot 34b having its eye 361) about the same warp thread but at its crossing with weft thread 29. This forms the first of the uncut tufts which is completely shown in the figure, reading from the top of the figure down. The looped tuft could, of course, be cut to form a closely adjoining pair of out tuft ends of adjacent knots, such as are shown in Figure 3 and other perspective views.

From the eye 36b of knot 342) the tuft yarn is continuous with the loop 311) and tuft 381) which is connected to form an uncut tuft with tuft 380 of the loop of knot 340. The eye 360 extends beneath the same warp thread 59 at its crossing with weft thread 3|. In the drawings this direc tion of passage is beneath because the fabric illustrates the tufts in the upper face of the fabric. The tuft 35c from this eye 36c cooperates with. another tuft 35d to form another uncut tuft corresponding with the first complete tuft at the upper part of the fabric.

In Figures 1a and 2a, the path of a continuous tuft yarn strand during the formation of the successive knots as above along the lengths of each pair of warp threads has been indicated by arrows. The description and the arrows emphasize the fact, elsewhere noted, that the tufts from the eyes in one pair of knots adjoin each otherclosely enough to be connected in the uncut pile-that the tufts from the loops of one knot in the first pair of knots considered, and of the next knot adjoin each other closely, permitting the same continuous connection and that this propinquity of the tufts from the eyes and the tufts from the loops of the knots successively warpwise along the lengths of the fabric continues, facilitating the formation and improving the quality of uncut pile and facilitating the formation of cut pile by permitting continuous weaving of uncut pile and subsequent cutting of it.

In Figures 1, 1b, warp threads 68 and 5| are shown which are not connected within the knots. Likewise, in Figures 1a. and 2a., warp threads 48 and 53 (in addition to the stufier warp threads of these last two figures) are shown as interwoven with the weft threads in the figures but do not pass through the knots. These may be included in other knots as stated or may be stuffer warp threads instead of or additional to stuffer warp threads 4|, 42 and 43, which latter can be dropped from Figures 1b, 13 and 14 or added to other figures if desired.

The suggested differences in the fabrics within which our knots are shown are given by way of illustration only and are not intended or designed to be complete, but explain a few only of the many variations of fabric within which our invention may be used.

In Figures 3 and 4 the knots correspond in all particulars with the knots in Figures 1 and 2 and no warp threads are found which are inactive in the sense that they do not pass through the knots shown. As in all of the figures, weft threads 24, 26, 28, 30 and 32 appear which do not pass through the knots. These alternate with the weft threads 25, 21, 29 and 3|, which do pass through the knots, and are woven in with the warp threads to form the fabric within which the tuft yarns are placed. They are highly beneficial in facilitating the beating up of the tufts during manufacture and in holding the tufts already inserted during the placing of the next tufts.

The tufts are all left-handed in Figures 3 and 4 and are of the same character in the same row running weftwise but are reversed, that is, lie alternately back to back and face to face, (though the hand of the knotted tufts is not reversed), in one row as compared with the knots in the next adjoining row along the warp thread length.

So far as the knots themselves are concerned the warp threads 45-52 of these figures, though preferably all chain Warp threads, need not all be chain warp threads.

In Figures 5 and 6 the eyes 36, 36a, 36b, 360 are formed about the warp threads 45, 41, 49 and 5! at and about their crossings with the weft threads 25, 21, 29 and 3|. The loops are brought around under the adjoining warp threads 46, 48, 50 and 52. The loops 31, 31a, 31b and 370 open in a direction opposite to that of the loops in Figures 3 and 4, and, therefore, make righthand woven knotted tufts, as distinguished from the lefthand knotted tufts, of Figures 3 and 4. Knots adjoining warpwise in different weftwise rows are reversed, in that they lie alternately back to back and face to face.

In Figures 7 and 8 each weft thread is composed of plural strands 24, 24a to 32, 32a, (intended to represent any plurality of threads or strands) which may be separate, either placed by a needle or by one or a plurality of passages of a shuttle and each plurality of strands 24, 24a etc., (whether what would be viewed as separate threads or merely separate strands) is treated as would be a single thread or strand in Figures 3, 4, 5, 6, 11, 12, 15, 16, 17 and 18. We recognize that whatever number exist of warp strands or threads or of weft strands or threads in a single warp thread position or in a single weft thread position, there are still a warp thread and a weft thread in each position to be included within each knot.

The knots of Figures 7 and 8 are left-hand knots as in Figures 3 and l and both strands of alternate weft threads pass through the eyes of the knots.

The weft positions of Figures 9 and 10 and of Figures 19 and 20 are filled by double weft strands which again may be viewed as a plu rality of weft strands making up a single weft thread, since they are treated alike, both going under and over the same warp threads, or as double weft threads, as preferred. The knots are right-hand Sehna type knots, and the weave corresponds generally with that of Figures 5 and 6, with the difference that a plurality of weft strands appear in each weft thread position shown in Figures 3 and 4. The plurality of weft strands is woven into the fabric and passes through the knotted tufts in the same manner as would be true of a single weft strand.

In Figures 11 and 12 alternate rows of tuft knots, lengthwise of the warp threads are of different hand, that is, in one weftwise row the tuft yarn knots are all right-handed and in the next weftwise row all left-handed, and so on throughout the fabric alternating the hand according to the warpwise alternations of the rows, but in each case the eyes pass around crossings of warp and weft threads, the eyes of one weftwise row, for example, passing about the crossing of warp threads 45, 4?, 49 and 5| with weft thread 25 and the eyes of the next weftwise row passing about crossings of the warp threads 26, 48, 56 and 52, (paired respectively with the warp threads considered in the previous row), with weft thread 27, and so on throughout the successive weftwise rows. It will be apparent that the loops in successive rows in these figures likewise pass about different warp threads, the loops in the upper row of the figure passing about warp threads 45, 48, 50 and 52, whereas those of the next row pass about warp threads 45, ll, 49 and SI.

In Figures 13 and 14 a fabric is shown which might be formed of either right or left-hand knots, but in fact shows left-hand knots and corresponds with Figures 3 and 4 except for the insertion of additional warp threads 40, 4|, 42 and 43, which are idle warp threads from the standpoint of the knotting function as they merely stiffen and strengthen the fabric without entering into nor passing through the knots,

which latter are threaded by the warp threads 45, 46, 41, 48, 49, 55, and 52. They are stuffer warp threads. It is apparent that the stuffer warp threads 40-43 would be just as truly idle and stuffer warp threads from the viewpoint above whether the rest of the warp threads be all chain warp threads or contain some stuffer warp threads.

Figures 15 and 16 on the one hand and 17 and 18 on the other show all right-hand knots and all left-hand knots, respectively, in which the eyes pass about wrap threads but not weft threads and the loops pass beneath crossings of warp threads and weft threads.

It will be apparent that as compared with the weft thread positioning of Figures 7, 8, 9 and the weft thread of Figures 3-6 and -18 is suited for application in a shuttle-type of loom, using a single thread which may or may not be a single strand. It will also be apparent that when the knotted tufts 34, 34a, etc. of these figures are woven into the fabric the loops 38 tend to bind the warp threads 45-52 to the weft threads 25, 21, 29, 3| and 33, making a fabric of improved quality; and that they are assisted in this strengthening or binding action, by the fact that each knot is anchored by the eye of the knot to another warp thread than that within its loop.

It is to be noted in Figures 15-18 that the knots in line warpwise in successive weftwise rows, as seen in Figures 15 and 1'7, all face in the same direction, as distinguished from the reversed facing or placing of knots emphasized in Figures 1a, 2, 2a and 3-14. Thus .in Figures 15 and 1'7 the terminals of the loops are spaced uniformly along the length of the fabric and are not arranged in pairs spaced an additional distance from adjoining pairs; and the tuft terminals of the eyes of the knots are spaced uniformly along the length of the fabric and are not arranged in pairs spaced differently from adjoining pairs than the spacing between the terminals of the pairs.

It will be noted that though there is a difference from the spacing in Figures 1a, 2 and 2a and Figures 3-14 in the particular above, the tuft terminals from the eyes are not in the same line across the fabric with the tuft terminals from the loops of knots in the same row nor with the tuft terminals from loops in the adjoining row, but are spaced in each case, (considered in a direction lengthwise of the fabric along the warp threads), by weft intervening between each two terminals, both between the tuft terminals of the loops and of the eyes within the same knots and between the eye terminal of one knot and the loop terminal of the next.

It will be obvious that the same uniformity of spacing is applicable to knots where the eyes surround the crossing of weft thread and warp thread, as in the earlier figures, as is applied in Figures 15-18 where the loops surround these crossings; the only condition to secure this being that the knots shall face the same way instead of being reversely faced, as in the earlier figures.

The construction of Figures 19 and is the same as that of Figures 15 and 16, including the positioning of the crossing within the loop instead of within the eye and the uniform placing of the knots along the lengths of the warp threads, (as distinguished from reverse positioning of them as in Figure 2), except that two weft thread strands are carried together in Figs. 19 and 20.

In this fabric the weft threads and 25a, to 32 and 3211 inclusive, are inserted with a needle as in Axminster type looms, and the knotted tufts can be woven either as right or left-hand knots.

In all of the forms our invention protects the edges of the fabric from unravelling where the fabric is cut, holding the warp threads to the weft threads and to the adjoining warp threads and minimizing the necessity for artificial methods of prevention of unravelling, such as impregnaaion of the back of the fabric. Not only are the crossing warp and weft threads held together at each knot but the crossed warp and weft threads are bound to the adjoining warp thread giving additional security.

It will be evident that the illustrations given show a few only of the combinations possible indicating the range of the combinations rather than attempting to disclose any considerable number of them.

It will be evident that such illustrations as that in Figures 7 and 8 where plural weft threads are illustrated as separated are intended for the purpose merely of emphasizing what is true of any of the other figures, namely, that each weft position may be occupied by what is regarded as a single weft strand or thread or any plurality of strands or threads, which have been viewed by us as a single strand for convenience only, and which, if plural, may be laid by a single or multiple passage of a shuttle or needle. It is therefore recognized that the knotted tufts can be woven into the fabric in any number of combinations of right or left hand knots, or in any number of alternating rows of right and left hand knots, or in any combination of reverse formation of knots, and any Variation of combinations using this knotted tuft with a shot of weft in a single strand or any multiple number of strands, between the two tuft ends, becomes a part of this disclosure and specification.

It will be evident that the question of right or left-hand formation, the facing of the knots reversely or in the same direction and the number of warp strands or threads and/or weft strands or threads enclosed within the eye or the loop of the knotted tuft will depend upon the location intended for the tuft ends, the proportioning and placing of weft or filler threads inserted, the type of loom in which the fabric is being woven, the general design and other contributing factors.

It will be evident that the fabric shown by those figures having single weft strands only, namely, 1-6 and 11 to 18, is best suited to construction upon a loom in which the weft thread is laid by a shuttle, and that the fabric of Figures 7-10, 19 and 20 is best suited to weaving by looms in which the weft thread is laid by a needle as in the Axminster type of loom.

It will be further evident that the placing of the knots back to back and face to face alternately represent an advantage in the placing of the knots which will be used or not according to the wish of the designer, since the new knotted tuft is capable of being placed either in this manner or with the knots all facing the same way; and this is true whether the knots be all right-hand or all left-hand, or alternating right and left-hand, as in Figures 11 and 12.

Our improved knotted tufts, particularly when placed oppositely facing in successive rows, are well suited to continuous tuft yarn application, by which the loops of adjoining knots are connected continuously in one position and the eyes in the next, also permitting the tufts to remain uncut or to be subsequently cut as desired.

It will be obvious that the knots can be constructed by hand and are not essentially woven from continuous tuft yarn; the continuous tuft yarn form representing a very advantageous method of formation, which may or may not be used.

It will be evident that the continuous tuft yarn formation disclosed in Figures 1a and 2a is applicable to series of knots extending upon the different pairs of warp threads indefinitely along the lengths of the warp threads so that in Figure 3, for example, before severance, tuft yarn end 38 is continuous with tuft yarn end 380,, tuft yarn end a is continuous with tuft yarn end 35b, tuft yarn end 38b is continuous with tuft yarn end 380, etc.

In view of our invention and disclosure, it will be understood that this application is intended to cover any variations, uses or adaptations of this invention, including such departures from the present disclosure as come within the known or customary practice in the art of weaving and as may be applied to the essential features herein set forth and as fall within the spirit and scope of the invention, or the limits of the appended claims.

Having thus described our invention what we claim as new and desire to secure by Letters Patent is:-

1. The method of forming a tuft yarn to bind together warp threads and weft threads interwoven with the warp threads and crossing them, which consists in forming a knot from the tuft yarn with an eye and a loop, one of which passes about the warp thread and the weft thread at the crossing to bind them together and the other of which passes about an additional warp thread to bind it to the first warp thread and the weft thread.

2. The method of forming a tuft yarn to bind together warp threads and weft threads interwoven with the warp threads and crossing them, which consists in passing the tuft yarn about one of the warp threads and a weft thread at their point of crossing to form an eye and passing the yarn about an adjoining warp thread to form a loop, the eye and the loop both terminating in tufts.

3. The method of forming a tuft yarn to bind together warn threads and weft threads interwoven with the warp threads and crossing them, which consists in passing the tuft yarn about one of the warp threads and a weft thread at their point of crossing to form a loop and passing the yarn about an adjoining warp thread to form an eye, the eye and the loop both terminating in tufts.

4. The method of forming tuft yarn to bind together warp threads and weft threads interwoven With the warp threads and crossing them, which consists in progressively passing tuft yarn about one of a pair of warp threads and a weft thread and separately about the other warp thread to form a Sehna type knot of which the eye and the loop each passes about a warp thread and one passes about a weft thread also at its crossing with the warp thread, providing tuft material for a tuft and then forming a knot in an adjoining row continuous with the first formed knot, and so on, having the tuft formed at the conclusion of the formation of each knot connecting an eye to an eye of one pair of knots in adjoining rows and a loop to a loop for the next row of knots, and

so on.

5. The method of forming tuft yarn to bind together warp threads and weft threads inter Woven with the Warp threads and crossing them, which consists in progressively passing tuft yarn about one of a pair of warp threads and a weft thread and separately about the other warp thread to form a Sehna type knot of which the eye and the loop each passes about a warp thread and one passes about a weft thread also at its crossing with the warp thread, providing tuft material for a tuft, and then forming a knot in an adjoining row continuous with the first formed knot, and so on, having the tuft formed at the conclusion of the formation of each knot connecting an eye to an eye of one pair of knots in adjoining rows and a loop to a loop for the next row of knots and so on, and subsequently cutting the tuft material.

6. The method of using a pile yarn knotted tuft to bind together warp and weft threads of a fabric, which consists in forming the knot with an eye and a loop, one of which binds a warp and a weft thread and the other of which binds to them an adjoining warp thread, forming a second knot in line with the first along the warp threads facing oppositely from the first knot, and so on whereby the loop tuft of one knot adjoins the loop tuft of the next and the eye tuft of each of these knots adjoins the eye tuft of the knot next to it and so on.

'7. The method of strengthening the body of a tufted fabric having warp and weft threads, which consists in binding the warp threads to the weft threads of the fabric by Sehna knots formed in the tuft yarn by passing the tuft yarn about both warp and weft threads at the same eye or loop of the knot.

8. The method of forming successive Sehna type knots about warp threads in a fabric having also weft threads, which consists in forming the eye of one knot first and the loop last and in the next adjoining knot along the lengths of the warp threads forming the loop of the knot first and the eye last, the third knot being formed with the eye first and the loop last and so on, the eye of each knot being formed about a weft thread as well as a warp thread, a different weft thread for each successive knot along the lengths of the warp threads.

9. The method of weaving knotted tufts within the warp threads and weft threads of a fabric, which consists in placing weft thread between adjoining knots and forming each of the knots about both warp thread and weft thread whereby weft thread bound by the knots alternates with weft thread between the knots.

10. The method of weaving Sehna type knots within a fabric having warp threads and weft threads, which consists in weaving knots successively along the length of a pair of warp threads, having eyes of one pair of adjoining knots adjoining and passing about a weft thread as well as a warp thread for each eye, and having the loops of the next adjoining knots adjoining and passing about a second warp thread of the pair and placing weft between the adjoining eyes and between the adjoining loops to hold one of the knots in position.

11. The method of weaving Sehna type knots within a fabric having warp threads and weft threads, which consists in weaving knots successively along the length of a pair of warp threads, each knot having an eye and a loop, one

of which passes about a weft thread over the tuft yarn as well as about a warp thread, the eye tufts of two adjoining knots being adjacent and the loop tufts of these knots and the next adjoining knots being adjacent, and in passing weft thread between the knots of successive rows in addition to the weft thread passed over the tuft yarn.

12. In a fabric, a first warp thread, a weft thread forming a crossing with said first warp thread, a second Warp thread spaced from the first warp thread and a tuft yarn knot having an eye and a loop, one of them about the first warp thread and the weft thread at the crossing and the other about the second warp thread.

13. In a fabric, a warp thread, a weft thread forming a crossing with the warp thread, a second warp thread spaced from the first warp thread and a tuft yarn knot having an eye and a loop, the eye about the first warp thread and weft thread at the crossing and the loop about the second warp thread.

14. In a fabric, a warp thread, a weft thread forming a crossing with the warp thread, a second warp thread spaced from the first warp thread and a tuft yarn knot having an eye and a loop, the loop about the first warp thread and weft thread at the crossing, the eye about the second warp thread.

15. In a fabric, a plurality of pairs of warp threads, weft threads interwoven with the warp threads and forming crossings with the warp threads and knotted tufts, each having an eye and a loop, the eye of which includes a warp thread and a weft thread at the crossing and the tuft terminals of which lie in diagonally opposite positions with respect to the crossing of the same weft thread with the other warp thread of the pair.

16. In a fabric, a plurality of pairs of warp threads, weft threads interwoven with the warp threads and forming crossings with the warp threads and knotted tufts, each having an eye and a loop, the loop of which passes about a warp thread and a weft thread at the crossing and the tuft ends of which lie in diagonally opposite positions with respect to said crossings.

17 In a fabric, a plurality of pairs of warp threads, weft threads interwoven with the warp threads and forming crossings with the warp threads and knotted tufts, each having an eye and a loop, one of which includes a warp thread and weft thread at the crossing of one warp thread of a pair and the other of which includes the other warp thread of the pair, and stuffer warp threads between adjoining pairs of warp threads.

18. In a fabric, a plurality of pairs of warp threads, weft threads interwoven with the warp threads and forming crossings with the warp threads and knotted tufts each having an eye and a loop, one of which includes a warp thread and weft thread at the crossing of one warp thread of a pair and the other of which includes the other warp thread of the pair, the lines between the tufts in successive rows being diagonal to the directions of both the warp threads and the weft threads.

19. In a fabric, a plurality of pairs of warp threads, weft threads interwoven with the warp threads and forming crossings with the warp threads and knotted tufts each having an eye and a loop, one of which includes a warp thread and weft thread at the crossing of one warp thread of a pair and the other of which includes the other warp thread of the pair, there being weft thread alternating, over the tuft yarn within the knots and between successive weftwise rows of knots.

20. In a fabric, a plurality of Warp threads, a plurality of weft threads interwoven with the warp threads, and knotted tufts forming loops and eyes in rows warpwise of the fabric, tying together in each row the same warp thread within the loops and different weft threads within the successive eyes.

WALTER A. RICE. FRANK G. SHINN. 

